F3SP User`s Manual
Contents
1. 24 2 2 2 13 7 OPERATING 5 422 14 71 DIP SWITCHES CONFIGURATION scccsccssscesstessseeesteesteeeneesneenseeenneeens 14 7 2 MUTING FUNCTION need 15 DESCRIPTION e detener cire tees 15 7 2 2 INSTALLATION CRITERIA sss 15 759 OVERRIDE or mc t e re UTE 19 7 4 STARTING THE OVERRIDE FUNCTION 19 7 5 MUTING RESTRICTIONS MUTING FUNCTION 19 7 6 EEDAINDIOCATOR tenete rebote eee emere era 20 8 tud ec eden fn 21 9 ROUTINE 4 244 4 21 10 GENERAL INFORMATION AND USEFUL DATA 22 11 TECHNICAL 23 12 INDICATION 24 12 1 INDICATION NORMAL 4 4 41 24 12 2 INDICATION FOR TROUBLE 24 13 OVERALL DIMENSIONS 224 04 49 4 26 4 of 28 F3SP U2P TGR User s manual 1 1 BEFORE USING THE DEVICE 11 GENERAL INSTRUCTIONS Read this manual and the light curtain s manual completely Be sure the information provided is understood before attempting to operate the light curtain Keep the manual in a secure2. flammable or explosive gas Do not use the cellular phone or transceivers near the control unit The control unit has been designed to the following standards IEC 61496 1 1997 Safety of machinery electro sensitive protective devices General requirements and test FDIS IEC 61496 2 1997 Safety of machinery electro sensitive protective devices Particular requirements for system using active opto electronic devices Page 6 of 28 F3SP U2P TGR User s manual 3 OPERATION The control unit has two independent microprocessors forming a system with two independent channels as required in the standards When one or both safety light curtains are interrupted the control unit opens both safety output contacts and indicates which light curtain has been interrupted by four green LEDs locating on the front panel A 7 segment display supplies information on the state and on probable failures The control unit can work in two different modes see sec 7 as follows 1 Automatic mode The control unit automatically starts after power ON and automatically restarts after the object in the detection zone is removed 2 Interlock mode Returns to the normal operating mode only after the object has been removed and the RESET button has been pressed While the control unit is connected to power do not change dip Switch to avoid influence on the system safety The control unit needs following two buttons e TEST This
3. be arranged in such a way that the material is recognised even when it is on a pallet or other transporting medium In case of different transport speeds through the muting area consideration must be used on the muting duration All the light curtains and the muting sensors must be arranged in such a way that the previous material has already passed the last muting sensor before the new material has reached the first muting sensors Muting E lamp Test amp Reset button Pd F3SP U2P TGR control unit Power cable Muting cable RX cable TX cable Page 15 of 28 F3SP U2P TGR User s manual Application with four muting sensors Muting sensors connection 24 Voc contact of A1 2 N C 11 MUTE C L 1 1 1 oo op 10 MUTE D m Cm contact of A2 4 9 MUTEA ELIO j eea 8 MUTEB B2 A2 Bi Al contact of B1 4 a d1 eo e F3SP U2P TGR D 42 terminals contac og 4 Application with two muting sensors Muting sensors connection 24 NC 11 MUTEC N C contact of A A 10 MUTED 9 MUTEA 8 MUTEB contact of F3SP U2P TGR terminals D minimum distance so that the muting sensors keep active the request it depends on the parcel length D L di necessary maximum distance so that the muting request is accepted it depend
4. control unit must be located in a cabinet with protection degree of at least IP54 Muting sensors must be positioned so that they cannot be activated inadvertently by personnel The control unit does not have power supply terminals for muting sensors Page 18 of 28 User s manual F3SP U2P TGR User s manual 7 3 OVERRIDE This function makes it possible to force a muting condition if necessary by starting the machine despite one or both safety light curtains having been interrupted by the object Thus enabling removal of the material from the protected area when it has been stuck in the beam of the safety light curtains due to a failure Suppose that a pallet has stopped before the light curtains the conveyor belt cannot be started again because the control unit after having detected one or more interrupted light curtains will not close the output contacts thus making it impossible to free the controlled area By starting the override function it will be possible to carry out this operation 7 44 STARTING THE OVERRIDE FUNCTION Switch off the control unit Make sure that the TEST and RESET buttons are connected N C for the TEST button N O for the RESET button e Switch on the control unit e During the countdown displayed press together the TEST and RESET buttons and keep pressing Do not press the buttons before the countdown Otherwise a failure occurs because a self test is carried out to check that th
5. on If the alignment of the light curtain 2 is correct the LED 3 and 4 are turned on e After the alignment turn off the power supplying the control unit close the test contact and power the control unit again e Wait for the control unit to carry out the initial tests visualising on the display a count down which indicates the control unit activity e At the end of this operation the display will visualise letter A indicating the active state of the control unit Carry out all the checks described in the final checks and in the routine maintenance operations During aligning operations or normal working check that the light curtains connected to the same or other units do not interfere with each other Modifying their mutual position for instance by positioning emitter on the other receiver side Page 13 of 28 F3SP U2P TGR User s manual 7 OPERATING PROCEDURES DIP SWITCHES CONFIGURATION The configuration shown in the table below must be selected on both sets of dip switches on the internal board The description corresponding to the pre chosen selection is shown below To configure dip switch remove the lateral plastic cover with screwdriver as shown in the figure below 1 Function swi SW m not used 2 2 2 Function r Off muting A B act on the light curtain 1 muting C D act on the light curtai
6. reset muting and override Container plastic container for installation on a din omega guide Protection class of control unit IP 20 Protection class of the cabinet containing the control unit IP54 at least Weight control unit 600 g Features of fuses relay board F1 F2 internal resettable fuses 3 15A T 250V Features of fuses muting lamp internal resettable fuse 315mA T 250V Muting lamp incandescent lamp 24 V 3 W min 300 mA max Page 23 of 28 F3SP U2P TGR User s manual 12 INDICATION CODES 12 4 INDICATION IN NORMAL OPERATION w CS restutoris pressed Ouput contac ar opened Override function is activated Normal cycle Output contacts are closed Light curtain is interrupted in automatic mode Output contacts are opened Interlocked condition Output contacts are opened 12 2 INDICATION FOR TROUBLE SHOOTING cone Am Error of muting lamp Irreversible system error or error on the 2 output contacts EE Wrong muting sequence request Page 24 of 28 F3SP U2P TGR User s manual If failure code is shown on the display the user must only carry out the procedures indicated in the column relating to that failure and described as follows 1 check that the muting lamp is not blown or incorrectly connected otherwise contact your distributor to replace the fuse follow the instruction on paragraph 10 2 this type of failure means that the unit cannot
7. to carry out a muting request if the light curtain is interrupted and the output contacts are in the opened state E or F code on display beams are interrupted 7 6 LED INDICATOR The operator can see the control unit status by a bicolour LED four green LEDs and a 7 segment display The LEDs have following meanings RED GREEN LED bicolour LED RED The safety light curtain s detect an object or the control unit detects an error which can be possibly recovered by pressing the RESET button and the output contacts are opened GREEN The safety light curtain s are working correctly and there are no detected objects and the output contacts are closed e Four GREEN LEDs When they are lit the safety light curtain s work normally and no object is detected the output contacts are closed e 7 segment display See sec 12 the description of the coding is given Page 20 of 28 F3SP U2P TGR User s manual 8 FINAL CHECKS cg Check that the area protected by the safety light curtain is free from any obstacle check the correct triggering of the output contacts opening by interrupting the protection rays red LED switched on controlled machine stopped CAUTION If the red LED switches on and off check the correct mechanical installation NOTE This check must be repeated each time you move or mechanically re align the safety light curtains and muting sensors ROUTINE MAINTENANCE Be sure to conduct inspection c
8. F3SP U2P TGR User s manual F3SP U2P TGR Safety control units Type 4 For use with 1 or 2 pairs of safety light curtains USER S MANUAL Page 1 of 28 F3SP U2P TGR User s manual The device conforms with the EC requirements in compliance with the following standards Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Machinery Directive 98 37 EC IEC 61496 1 1997 DIN V VDE 0801 1990 and amendment A1 1994 EN 50081 2 1993 EN 55022 1994 DIN EN 60204 1 1993 EN 50178 1997 PRODUCER TECHNO GR s r l via Torino 13 15 10046 Poirino TO ITALY Tel 39 011 9452041 FAX 39 011 9452090 Version 1 0 date 1 0 date 2 14 2001 Page 3 of 28 F3SP U2P TGR User s manual INDEX 1 BEFORE USING THE DEVICE 5 11 GENERAL INSTRUCTIONS ttes 5 1 2 ROUTINE MAINTENANCE 1 4 12 2 2 20 22 0001 20 5 1 3 PRECAUTION OF SAFETY tice ccce ctetu liceret heuer vedo 5 2 GENERAL INFORMATION eren rennen nennen nnne nnn nnns 6 3 OPERATION iiec 7 4 PRECAUTIONS AND INSTALLATION CRITERIA 8 41 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE 8 b iic nitet acude nao cda citus quin cai p 9 5 1 TERMINAL BLOCK ASSIGNMENT 9 5 2 WIRINGr EXAMBLE intret ettet etes teen pata 10 6 ALIGNMENT
9. X1 RX2 OUT RX2 NC NC A p c A B 7 108 49 2 2 2 2 25 20 27 28 9 3 3 D a N 52 ac al 2 gt 5 8558 3 5 P c E 9m a E 9 9 r4 2 5 a 5 22 8 8 z E 8 5 8224 6 9 6 s 2 5 gt o 9 Sync 1 red black 5 Sync 2 gray black 6 gt Sync 1 red black 5 Sync 2 ray black 6 1 4 Sync 2 Xgray 3 g g g _ gt gt _ gt ca S 4 SS Emitter Receiver Emitter Receiver Page 10 of 28 User s manual F3SP U2P TGR Connection of two F3S B light curtains to the control unit F3SP U2P TGR MUTING SENSORS 8 gt 8 Hj ES MUTING 24VDC GND LAMP 5 28 528 828 858 5 m 4 4 SAFETY OUTPUT 1 SAFETY OUTPUT 2 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 B A D N C le TS HS RESET TEST MUTING OUT1 OUT2 LAMP TX1 TX2 RX1 OUT RX1 RX2 OUT RX2 NC NC 4 NC NC 5 B ELE B 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 8 2 E 4 P d 4 PN al d FA 5 8 8 S 2 8 8 aa 5
10. and convenient location and refer to it as necessary To guarantee correct installation carefully follow the instructions of this manual Do not touch non insulated cables unless they have been isolated Make sure that the cables connected to the control unit are not taut and that they do not hinder the movement of persons or objects The control unit does not contain parts subject to maintenance Do not open the control unit for any reason and in case of failure return to your distributor indicating the fault and the operation period A qualified person as determined by local regulations must confirm that installation inspection and maintenance is implemented correctly Failure to do so may result in loss of life or serious injury 1 22 ROUTINE MAINTENANCE Please refer to sec 9 and the light curtain instruction manual OMRON Europe refuses to accept any responsibility for damage to persons or objects due to the incorrect use installation of the control unit 1 3 PRECAUTION OF SAFETY The following symbols are used for highlighting items in order to ensure safe and proper use of the F3SP U2P TGR Items highlighted are critical for safe operation and must be heeded at all times Caution AN Warning Page 5 of 28 F3SP U2P TGR User s manual 2 GENERAL INFORMATION The safety control unit of the F3SP U2P TGR series has been designed to be used with the dedicated light curtains Please refer to sec 11 It ca
11. be used and it is necessary to contact your distributor 3 check the correct wiring and sensor positioning for muting sequence Indirect discharge with 6kV or direct discharge with 8kV may cause influence to the 7 segment display and the output contacts may open this situation does not compromises the safety functioning of the light curtain Page 25 of 28 F3SP U2P TGR User s manual 13 OVERALL DIMENSIONS FRONT VIEW SIDE VIEW 120 mm 3 SZ 150 mm Control unit F3SP U2P TGR TOP VIEW 0000000000000000 oof joo 75 mm O0000000000000000 Page 26 of 28
12. dditional distance calculated or defined based on the optical resolution of the light curtain Page 8 of 28 F3SP U2P TGR 5 CONNECTIONS 5 1 TERMINAL BLOCK ASSIGNMENT TERMINAL OUTER CONNECTION 1 2 Connect to the 24 VDC power supply note the polarity indicated on the label RESET button connect a normally opened contact N O TEST button connect a normally closed N C User s manual o Connect the muting lamp Switch other Switch other Switch others Switch others Terminal not used 13 14 OUT1 safety output 1 with contact 15 16 OUT2 safety output 2 with N O contact 17 18 Power supply transmitters TX1 for light curtain 1 24VDC wire to terminal 17 OV wire to terminal 18 Terminal not used Power supply transmitters TX2 for light curtain 2 24VDC wire to terminal 21 OV wire to terminal 22 Terminal not used Power supply receivers RX1 for light curtain 1 24VDC wire to terminal 25 OV wire to terminal 26 Connect to the PNP output of the receivers RX1 of light curtain Control output 1 wire and Control output 2 wire to terminal 27 and 28 Two control outputs must be used No use of light curtain1 Use of only light curtain 2 It shall be connected the terminal 27 and 28 to terminal 25 Power supply receivers RX2 for light curtain 2 24VDC wire to terminal 29 OV wire to terminal 30 Connect to the PNP output of the recei
13. e buttons are not locked e The override function has been activated The display visualises three overlapping segments The muting lamp blinks to signal the light curtain disconnection e The maximum duration of the override function amounts to 60 seconds after that the light curtain is connected again even if the buttons are pressed If the buttons are released before this time has elapsed the override function will be immediately stopped 7 5 MUTING RESTRICTIONS muting function a The muting operation must occur according to the correct timing sequence For the two muting channels it is necessary to activate input MUTE A or MUTE C at first and then input MUTE B or MUTE D within 3 seconds If not the muting sequence will not be activated A wrong sequence on muting shows a failure on the display and the output contacts are open until the RESET button is activated Page 19 of 28 F3SP U2P TGR User s manual b When the muting state is active an object can remain for a period of no longer than 60 s otherwise the muting function is switched off This mechanism is optional and can be deactivated when the control unit is set up see page 13 For the cases the muting function is automatically disabled because of time out the request must be cut out override function or removing object and rest to generate the following muting state MUTE STATE 60 S max It is not possible
14. ei dq 8 2 508 8 amp a o a N 2 3 6 5 9 s 9 8 gg 3 9 5 9 8 2 9i z E S 9 9 5 58 zs E x 8 z 9 a of 8 28 o a 5 88 8 8 x s S al E 3 3 4 2 6 2 5 9 6 81 6 6 RS 485 B Pink 6 RS 485 B Pink 6 RS 485 A Gre 5 RS 485 A Grey 5 Emitter Receiver F3S B Emitter Receiver F3S B Page 11 of 28 F3SP U2P TGR User s manual Notice e configure the control unit in such a way that it works with one single light curtain it is necessary to connect the terminal 31 and 32 to the terminal 29 e DC power supply units must satisfy all the conditions below in order to AN conform to the application directives 1 The power supply voltage should be within rating 24VDC 10 2 The power supply conforms to EMC Directive industrial environment and LOW Voltage Directive 3 The power supply uses double insulation between the primary and secondary circuits 4 The power supply should include over current protection limited up to 4 A 5 The power supply maintains an output holding time of at least 20ms AN e The transformer which is necessary to power the system must conform to standard EN 60742 double insulation or with equal insulation for instance VDE 0551 AN e It is necessary to protect the control un
15. hecks as below regularly Check that there is no person in the hazardous area before operator turns ON the power Check that the unit locks by inserting a moving object through the detection zone By opening the test contact check that the output contacts are opened red LED switched on and machine stopped Make sure that the access to the hazardous areas is not possible from any non protected area and that the minimum distance from the safety light curtain to the hazardous part is not less than the result calculated with reference to the formula reported at paragraph 4 1 Make sure the installation satisfies one of following conditions 1 The machine connected to the control unit has an interlock function 2 The controller uses interlock mode 3 It is not possible for a person to stop between the safety light curtain and the hazardous parts of the machine Make sure that there is no outer damage to the safety light curtain and or the outer electrical connections Make sure that the response time including the safety light curtain and the machines does not exceed the established limits If failure occurs all functions of the control unit shall be tested The frequency of these operations depends on the special applications and operative conditions Page 21 of 28 F3SP U2P TGR User s manual 10 GENERAL INFORMATION AND USEFUL DATA Safety MUST be part of our consciousness The safety devices are only effective if ins
16. is used to check if the whole system works effectively By pressing the TEST button opening of the contact this simulates the interruption of one or both safety light curtains This operation makes the machine stop so the system checks can be made according to the established time and modes RESET Itis used to reset the interlock see above 2 Interlock mode It is also used to restart after the cause of an error is removed see sec 12 In addition the control unit can be set for the muting function This function can be selected by setting of dip switches inside the control unit Page 7 of 28 F3SP U2P TGR User s manual 4 PRECAUTIONS AND INSTALLATION CRITERIA The safety products used must be suitable for the required application other influences must also be taken into account such as room temperature electromagnetic interference intense light sources etc 4 1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE The safety distance S must be sufficient to guarantee that the hazardous area cannot be reached by the operator up to the moment in which the hazardous movement stops Please refer to the following formula and or the safety light curtain s instruction manual 5 5 safety distance T T1 T2 3 whereas T1 machine response time in seconds T2 light curtains response time in seconds T3 controller response time in seconds speed of the body approaching the hazardous area a
17. it with an outer fuse having nominal interruption current equal to 1 A e The TEST and RESET buttons must be positioned in such way that the operator can see the protected area when he restarts or carries out a test or override operation CET e The muting lamp for signalising active muting must be positioned in a place where it can be seen from any operative point e Read the paragraph relating to the muting function and its use for the positioning of the activation sensors of this function AN e Both safety contacts OUT1 and OUT2 must be connected If the machine has a single locking circuit the two normally opened contacts must be connected in series e The connection cables of the light curtains of muting request test and reset must be masked with minimum section 22AWG The cable shield braids must be all earthed on the control unit side e Be sure to isolate the power prior to wiring Page 12 of 28 F3SP U2P TGR User s manual 6 ALIGNMENT PROCEDURE After having carried out the correct mechanical assembly and the correct connections as described in the previous paragraphs it is necessary to align the light curtains Follow the operating guide as follows e Turn off the power supplying the control unit e Open the test contact e Power the control unit e Align the light curtain by observing the LEDs on the control unit If the alignment of the light curtain 1 is correct the LED 1 and 2 are turned
18. n 2 NOTE Configure the two dip On Forbidden switch in the same way otherwise code 8 is displayed which means a failure 3 Function 4 function Off muting 60 s interlock mode On muting 5 automatic mode e The control unit is Factory default set with the following configuration Automatic mode the maximum duration of the muting sixty seconds To configure dip switch remove this cover with screwdriver A 17 A 17 Page 14 of 28 F3SP U2P TGR User s manual 7 2 7 2 1 7 2 2 MUTING FUNCTION DESCRIPTION The muting function makes it possible to inactivate one or both light curtains in order to allow for instance the objects passage without stopping the machine As required by the standard the control unit has two inputs for the activation of this function Two separate muting functions are present It is necessary to position and connect the muting sensors in order to avoid undesired muting inputs It is important to remember that the muting function forces the system to work and for this reason it must be used with care To use the muting function it is necessary to connect the muting lamp otherwise the control unit is locked INSTALLATION CRITERIA 1 2 3 The muting sensors must recognise the material namely pallets vehicles etc over its full length The sensors must
19. nnot be connected to other light curtains The control unit complies with the requirements for safety devices of type 4 in accordance with the latest international standards stated in IEC 61496 1 However the safety system category depends on the light curtain s type as follows Type 4 light curtain Safety system category 4 Type 2 light curtain Safety system category 2 The DIN OMEGA mounted control unit is protected to 20 by a plastic housing It has 32 screw terminals to which it is possible to connect with 1 or 2 pairs of light curtains This control unit has the double muting function This function makes it possible to inactivate one or both light curtains in order to allow for instance the objects passage without stopping the machine The override function represents the possibility to force the system The override function allows the system to be manually overridden allowing material to be cleared from the muting area if a fault has occurred Both the muting and the override functions force the system to work Therefore activating these functions needs some precautions to avoid the reduction in safety see sec 7 2 The presence of a limb or an object interrupting one of the light curtains will open the safety outputs and consequently stop the connected machine It is necessary to install the light curtains in such a way that bypassing of any person is not possible Do not install the control unit in the corrosive
20. s on object speed dmax Cm v m s x 3 s x 100 This distance must not allow both sensors and the muting cycle with the passage of a person Page 16 of 28 F3SP U2P TGR User s manual Application with eight muting sensors for output and input control Safety light curtain 2 contact o contact o contact o contact o contact o contact o contact o contact o C1 C2 D1 D2 A1 A2 B2 Safety light curtain 1 Muting sensor connection Muting enable to light curtain 2 from robot system control 11 MUTEC 10 MUTE D 9 MUTEA 8 MUTEB F3SP U2P TGR terminals Muting enable light curtain 1 from robot system control Page 17 of 28 F3SP U2P TGR The TEST and RESET buttons must be positioned in such a way that the operator can see the protected area when he carries out reset test or override operations that it can not be activated from inside the hazardous area The muting lamp for indication active muting must be positioned in a place where it can be seen from any operative point If the muting sensors are installed close to the light curtains it is necessary to install the sensor receivers near the light curtain emitter side to avoid interference The system is protected from possible failures due to the cable damage it is necessary to prepare the wiring to avoid damage to the connection cables The
21. talled correctly by respecting the guidelines laid down in the relevant standards These devices should be installed by a competent person Please contact our office for advise on service or installation Problems due to voltage interruption on the power supply may cause temporary openings of the outputs This is not damaging to the safety PES and control unit The guarantee is complete for a period of 12 months starting from the delivery date of the device Defects which are clearly due to damage caused by an incorrect use accidental causes or catastrophic events are not covered by the guarantee In case of failure send the light curtain to your distributor See the back cover Please indicate the detected failure and the operational period Page 22 of 28 F3SP U2P TGR User s manual 11 TECHNICAL DATA This is following the combinable light curtains Type 4 light curtain F3S Axxx series Type 2 light curtain F3S Bxxx series Note that all safety light curtains to be used are certified according with the EN61496 1 Type 4 Type 2 al input 420 mA max for any model Voltage 24 Vdc 10 Number of light curtains 2 pairs max Indicators 4 green LEDs 1 green red LED 1 digit display diagnostic Response time lt 18 ms Working temperature 10 55 C Moisture from 15 to 95 not condensing Output contacts 2 NO 3 15 A max 250 Vac cos 0 6 1 protected by a resettable fuse Outer controls test
22. vers RX2 of light curtain 2 Control output 1 wire and Control output 2 wire to terminal 31 and 32 Two control outputs must be used No use of light curtain 2 Use of only light curtain 1 It shall be connected the terminal 31 and 32 to terminal 29 of the muting sensor Connect to the contact of the muting sensor photocell proximity nput of the muting A sensor Connect to the N O contact of the muting sensor photocell proximity nput of the muting D sensor Connect to the N O contact of the muting sensor photocell proximity nput of the muting C sensor Connect to the N O contact of the muting sensor photocell proximity Page 9 of 28 F3SP U2P TGR User s manual 5 2 WIRING EXAMPLE Connection of two F3S A light curtains to the control unit F3SP U2P TGR MUTING SENSORS 8 gt Qe MES I MUTING 24 VDCGND 2 LAMP T bad L Lus E 8 528 528 z pio 507 joo Ss pos e z I JL IH B SAFETY T OUTPUT 1 SAFETY OUTPUT 2 1 2 3 4 5 6 7 8 9 10 12 1 14 15 16 24VDC GND B A D N C MUTING LS SENSOR SENSOR Pd DA REST TEST MUTING OUT1 OUT2 LAMP TX1 TX2 RX1 OUT R
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